Co-processing of plastic waste in a cement kiln: a better option

This paper deals with the techniques to use plastic waste for co-processing in cement kiln for energy recovery. Plastics, a versatile material and friend to the common man, have now become one of the most serious environmental issues when it is discarded into the environment. The focus of this study is on eco-friendly disposal of plastic waste. Plastic is user-friendly, but because of its incomplete lifecycle, it has become a global issue. It is commonly disposed of by land filling or incinerating the waste, which adds to the pollution load at later stages. The authors' focus is on innovative techniques to use waste plastics in different proportions for the co-processing in cement kiln in order to highlight the energy recovery of the entire plant. It is a good solution to the waste disposal problems that arise due to plastic waste as well as municipal solid waste. The use of plastic waste as an alternative fuel for cement plants is suggested in this paper. The authors also promote this approach and suggest encouraging its calorific value utilization in the cement manufacturing plant. A systematic approach has been presented in this work to mitigate the energy consumption in the cement industries as well as environmental hazards due to plastic and municipal solid waste.

Dioxin emission and distribution from cement kiln co-processing of hazardous solid waste

Cement kiln collaborative disposal technology can not only dispose of hazardous waste but also provide energy for the cement industry. However, the addition of hazardous waste may promote the formation of dioxins in cement kilns. In this study, typical hazardous solid wastes, such as solidified fly ash, electroplating sludge, and industrial residue, were co-processed in a cement kiln with different feeding positions and different feeding amounts. The concentrations of dioxins in the flue gas, clinker, and precalciner furnace slag were investigated. The effect of adding mixed hazardous solid waste on the formation of dioxin was also studied. The results showed that the concentration of dioxin in the flue gas without added hazardous waste was 1.57 ng/m³, and the concentration varied from 1.03 to 6.49 ng/m³ after the addition of hazardous waste. In addition, the concentration of dioxin in the flue gas and solid samples increased substantially when the co-processing ratio doubled. The large amount of Cu in solidified fly ash promoted the formation of dioxins, while the higher S content in the electroplating sludge suppressed the formation of dioxins. Compared with the addition of single hazardous waste, the concentration of dioxin in precalciner furnace slag increases by about 300%. Furthermore, the distributions of isomers in the clinker and precalciner furnace slag were similar. 1,2,3,4,6,7,8-HpCDD and OCDD accounted for a large proportion of the mass concentration, and the contribution rate ranged from 48.7 to 82.0%. Most importantly, correlation analysis showed that the concentration of dioxin was closely related to the copper content, hazardous waste types and additive proportion, with correlation coefficients of 0.79, 0.83, and 0.89, respectively. This study provides a basis for exploring the high environmental benefits of disposing of hazardous solid waste by co-processing in cement kilns.

Ca2+ mediated mechanism of octa-brominated dioxin/furan formation via BDE-209 thermolysis: Introducing the Mayer bond order difference

Polybrominated dibenzo-p-dioxins/dibenzofurans (PBDD/Fs) that form during industrial thermal processes, such as the cement kiln co-processing of BDE-209, are highly toxic contaminants. Nevertheless, the formation mechanisms of octa-brominated dioxins/furans (OBDD/Fs), most PBDD/F congeners, and one precursor of the more toxic lower PBDD/Fs from BDE-209 have received little attention. In cement kiln co-processes, the Ca²⁺-mediated regulation of OBDD/F formation is still debated. In this study, simulation experiments revealed that the average brominating degree of PBDD/Fs was 7.8, indicating that OBDD/Fs are dominant congeners (93.6 % median). Density functional theory (DFT) calculations found a new transition state (TS1) with a lower energy barrier than that found in a previous study. Three major OBDD/F formation reactions suggested that the presence of Ca²⁺ was thermodynamically beneficial to the formation of OBDD/Fs. This promotion effect can be attributed to the transfer of electron density leading to a change in the Mayer bond order (MBO) among elements when Ca²⁺ was bound. Intriguingly, in the transition state structures of the Ca²⁺-bound and Ca²⁺-free systems, the MBO difference among the old and new bonds can reveal the difficulty of Ca²⁺-mediated OBDD/F formation reactions from BDE-209.

Pathways and influential factors study on the formation of PBDD/Fs during co-processing BDE-209 in cement kiln simulation system

The thermal processes of cement kilns are sources of polybrominated dibenzofurans and dioxins (PBDD/Fs); however, when co-processing decabromodiphenyl ether (BDE-209) soil in cement kilns, very few reports have investigated the mechanism of PBDD/Fs formation from BDE-209. Therefore, the pathways and factors that influence the formation of PBDD/Fs were investigated using Box-Behnken design (BBD) of the response surface methodology (RSM) at lab-scale. The PBDEs, HBr/Br₂ and PBDD/Fs emissions in flue gas from the simulated thermal process were analyzed using gas chromatography/mass spectroscopy (GC/MS), high-resolution gas chromatography/high-resolution mass spectrometry (HRGC/HRMS), and ion chromatography (IC). Density functional theory (DFT) was also used to further discuss the formation of PBDD/Fs. The major products of BDE-209 thermal decomposition in flue gas were 97.1% HBr/Br₂ (a.v. 26.6%/70.6%) > 2.7% PBDEs >0.2% PBDD/Fs. Formation of precursors were the main pathways for PBDD/Fs, and those precursors were dominated by higher-brominated PBDEs (heptã deca-BDEs); debromination of BDE-209 was also a crucial pathway for the formation of PBDD/Fs throughout the thermal process. Interestingly, it was easier to form HpBDD/Fs from OBDD/Fs than from PBDEs. The O₂ percentage and interaction factors of O₂ percentage, temperature, and CaCO₃ percentage have the largest influence on PBDD/Fs emissions and formation.

Unintentional persistent organic pollutants in cement kilns co-processing solid wastes

Co-processing solid waste in cement kilns has become increasingly widespread in recent years. Persistent organic pollutants (POPs) can be unintentionally produced and emitted from cement kilns, especially kilns in which solid waste is co-processed. Unintentionally produced POP formation and emission by cement kilns co-processing solid waste therefore need to be studied in detail to allow the potential risks posed by cement kiln co-processing techniques to be assessed. Many field studies and laboratory simulation experiments have been performed to investigate the formation and release of polychlorinated dibenzo-p-dioxins and dibenzofurans (PCDD/Fs). However, the formations, characteristics and emission factors of various emerging unintentionally produced POPs have not been comprehensively reviewed. Here, emissions of well-known unintentionally produced POPs (PCDD/Fs and polychlorinated biphenyls) and emerging unintentionally produced dioxin-like POPs (polybrominated dibenzo-p-dioxins and dibenzofurans, polychlorinated naphthalenes, and chlorinated and brominated polycyclic aromatic hydrocarbons) in cement kilns co-processing solid waste are reviewed, focusing on formations and influencing factors of those unintentional POPs. Data from field studies indicated that the main stages in which POPs are unintentionally produced in cement kilns co-processing solid waste are the cyclone preheater outlet, suspension preheater boiler, humidifier tower, and back-end bag filter. The raw material composition, chlorine and bromine contents, and temperature are the most important factors affecting POP formation. The homolog distributions and congener profiles of POPs formed unintentionally in cement kilns were compared, and it was found that larger amounts of less-chlorinated homologs than more-chlorinated homologs are emitted. Emission factors for various unintentionally produced POPs for cement kilns co-processing solid waste were summarized, and could be useful for compiling global emission inventories for pollutants covered by the Stockholm Convention. This comprehensive review improves our understanding of unintentional production and emissions of POPs by cement kilns co-processing solid waste.

Arsenic migration during co-processing of secondary residues from ammonium paratungstate production in cement kiln

To reduce the environmental pollution caused by ammonium paratungstate (APT) production in the Ganzhou area in China, simulated experiments in laboratory and field experiments in cement kilns were performed. The migration characteristics of As in secondary residues (thermometallurgy and hydrometallurgy residues) from APT production in cement kilns were similar, and As in the residues existed in the form of sulfides. When the residues were fed at the kiln inlet, the As in the residues was completely distributed in the clinker after a new mass balance of As was reestablished in a very short time. When the residues were fed at the raw mill, the total input rate of As was far higher than the total output rate. Therefore, a part of As was circulated in the cement kiln, and only a small part of As was distributed in the clinker. In addition, the As concentration in the flue gas and the leaching concentration of As in the clinker were far below the limit value in the Chinese standard. For feeding rates below that are used in the field experiment, co-processing of secondary residues in a cement kiln fed at the kiln inlet is environmentally safe. However, if the secondary residues are consistently fed at the raw mill, the As concentration in the flue gas may gradually increase.

Brominated dioxins and furans in a cement kiln co-processing municipal solid waste

A field study and theoretical calculations were performed to clarify the levels, profiles, and distributions of polybrominated dibenzo-p-dioxins and dibenzofurans (PBDD/Fs) in a cement kiln co-processing solid waste, with a focus on the PBDF formation mechanism. The raw materials contributed greatly to input of PBDD/Fs into the cement kiln. The PBDD/F concentrations in the raw materials were much higher than those in particle samples from different process stages in the cement kiln. The PBDD/F concentrations in the clinkers were 1.40% of the concentrations in the raw materials, which indicated that the high destruction efficiencies for PBDD/Fs by cement kiln. PBDD/F distribution patterns in particle samples collected from different process stages indicated the cement kiln backend was a major site for PBDD/F formation. PBDFs with high levels of halogenation, such as heptabrominated furans (HpBDF), were the dominant contributors to the total PBDD/F concentrations and accounted for 42%-73% of the total PBDD/F concentrations in the particle samples. Our results showed that co-processing of municipal solid waste in a cement kiln may influence the congener profile of PBDD/Fs, especially for the higher halogenated PBDD fraction. In addition, there were significant correlations between the decabromodiphenyl ether and heptabrominated furan concentrations, which is an indicator of transformation from polybrominated diphenyl ethers to PBDD/Fs. Theoretical calculations were performed and demonstrated that elimination of HBr and Br₂ from polybrominated diphenyl ethers were the dominant formation pathways for PBDD/Fs. These pathways differed from that for polychlorinated dibenzo-p-dioxins and dibenzofurans (PCDD/Fs).

Study on the evolution and transformation of Cl during Co-incineration of a mixture of rectification residue and raw meal of a cement kiln

The co-processing of hazardous waste in cement kiln can eliminate a large number of hazardous wastes, but the excessive existence of chlorine will affect normal operation of cement kiln. In this study, the partition of Cl in flue gas, fly ash and residual solid under different experiment conditions was obtained by using tubular furnace to incinerate mixtures of rectification residue and raw meal. The chlorine content in flue gas was determined using ion chromatography and the chlorine content in fly ash and residual solid was measured by high temperature combustion hydrolyzing-ion chromatography. The results showed that chlorine mainly existed in flue gas and residual solid, and only less than 3.5% of chlorine existed in fly ash. The incineration temperature had a significant effect on the distribution of chlorine in each part. The higher the incinerating temperature, the greater the proportion of chlorine in flue gas and fly ash. While temperatures were higher than 1300 °C, the proportion of chlorine in all parts remained basically unchanged, roughly 18:14:1. With the increase of the retention time, the proportion of chlorine in the residual solid decreased gradually, and the proportion of chlorine in the flue gas increased gradually. The distribution ratio of chlorine in each part remained unchanged after about 30 min. In addition, the chlorine content of the sample and the air flow rate had a relatively slight effect on the partition of chlorine. Based on these experimental results, some suggestions on the co-processing of hazardous waste in cement kiln were put forward.

Source identification and quantification of chlorinated and brominated polycyclic aromatic hydrocarbons from cement kilns co-processing solid wastes

Chlorinated and brominated polycyclic aromatic hydrocarbons (Cl/Br-PAHs) are widespread persistent organic pollutants (POPs) in environments. Identifying the new sources of Cl/Br-PAHs is important for implementing source control and reducing environmental risk. Although co-processing of solid wastes by cement kilns increased recently, the occurrences and characteristics of Cl/Br-PAHs as emerging POPs during cement kiln co-processing solid wastes have not been investigated. This study firstly investigated the occurrences, characteristics, and variations of Cl/Br-PAHs from four cement kilns co-processing different solid wastes. The concentration ranges of Cl-PAHs and Br-PAHs in stack gas samples from the investigated cement kilns were 15.6-94.1 ng m^-3 and 1.04-4.28 ng m^-3, respectively. Emission factors of Cl-PAHs and Br-PAHs through stack gases were 29.9-275 μg t^-1 and 3.0-8.3 μg t^-1, respectively. Variations of Cl/Br-PAHs in particle samples collected from different process stages within the cement kiln system indicated that the kiln end was the major formation zone for Cl/Br-PAHs. Congener profiles of Cl/Br-PAHs varied with the co-processed solid waste types, indicating the important influence of raw material compositions. Calculations of net emissions of Cl/Br-PAHs within the cement kiln systems suggested efficient destruction (87.6%-98.8%) of Cl/Br-PAHs by the cement kilns.

Destruction and formation of polychlorinated dibenzo-p-dioxins and dibenzofurans during pretreatment and co-processing of municipal solid waste incineration fly ash in a cement kiln

During a three-day industrial trial, municipal solid waste incineration fly ash (FA) was co-processed in a cement kiln after water-washing pretreatment for waste-to-resource conversion. All inputs and outputs were sampled to obtain the dioxin fingerprints. During washing, the relative contents of polychlorinated dibenzo-p-dioxins and dibenzofurans in FA, washed FA and sludge were basically the same and only a simple physical migration resulted. During drying, only physical processes resulted, which included volatilization and migration. Minimal dioxins residue remained in the clinker, cement kiln dust and flue gas, and the dioxins degraded completely. Through co-processing, the dioxins degraded obviously. The main compounds synthesized include 1,2,3,4,7,8-hepta-chlorodibenzo-p-dioxin, 2,3,7,8-tetra- chlorodibenzofuran and octa-chlorodibenzofuran. A comparison of dioxins fingerprints in the clinker, cement kiln dust and flue gas under baseline and co-processing conditions showed that co-processing had no effect on the cement kiln production. The baseline sample also contained a certain amount of dioxins, possibly because of the 'memory effect' and heterogeneous formations. The dioxins concentrations in the clinker and FA were far lower than the national standards. Thus, no environmental risk results during co-processing.

Spatial variation of PCDD/F and PCB emissions and their composition profiles in stack flue gas from the typical cement plants in China

Cement production processes are important sources of unintentionally produced persistent organic pollutants (UP-POPs), such as polychlorinated dibenzo-p-dioxins and dibenzofurans (PCDD/Fs), and polychlorinated biphenyls (PCBs). The emissions of PCDD/Fs and PCBs in the stack flue gases from eight typical cement plants in China were investigated in this study, including one wet process rotary kiln, three dry process rotary kilns and four vertical shaft kilns. PCBs exhibited relatively higher mass concentrations with the dioxin-like (dl) and indicator PCBs of 0.14-17.36 and 0.42-12.90 ng/Nm³, respectively. However, PCDD/Fs contributed most to the total toxic equivalent concentrations, with the proportions exceeding 90%. The international toxicity equivalency (I-TEQ) concentrations of PCDD/Fs varied greatly from 0.01 to 0.46 ng I-TEQ/Nm³ in stack gases, two of which exceeded the exhaust gas concentration limit of 0.1 ng I-TEQ/Nm³ established by the European Union Directive. In weight units, 1,2,3,4,6,7,8-HpCDF was the most abundant congener in the stack gases from various types of cement kilns, with the factions of 17.0-27.8%. TCDFs and PeCDFs were the first two most abundant homologue groups. 2,3,4,7,8-PeCDF was the largest contributor to the total I-TEQ. The emission factors of PCDD/Fs and PCBs in the eight cement kilns were estimated to be 0.01-1.35 μg I-TEQ/t clinker and 8.20 × 10^-4∼8.23 × 10^-2 μg World Health Organization TEQ (W-TEQ)/t clinker, respectively. No obvious differences of the PCDD/F and PCB emission factors were found among the varied cement production technologies.

Profiles of polychlorinated biphenyls (PCBs) in cement kilns co-processing solid waste

Co-incineration of sewage sludge in cement kilns can be used for its disposal. In the present study, samples were collected from three cement production runs where sewage sludge and other wastes (e.g. municipal solid waste, waste acid and wet sewage sludge) were co-processed. The samples were analyzed for polychlorinated biphenyls (PCBs). The dioxin-like (dl)-PCB concentrations in the stack gases from run 1, 2, and 3 were 344.6, 548.7, and 104.3 pg m^-3, respectively. The toxic equivalency (TEQs) values for runs 1, 2, and 3 were 5.6, 8.9, and 0.7 pg TEQ Nm^-3, respectively. Calculation of net emissions for the three runs indicated that the co-incineration of other waste in addition to sewage sludge in cement kilns would not increase emission of the dl-PCBs. PCB concentrations in samples from the suspension boiler and humidifier tower, kiln-end bag filter, and cyclone preheater were much higher than those in samples from the kiln head area, indicating that these stages will be important for controlling PCB formation. Chlorinated biphenyl (CB)-77, CB-105 and CB-118 were the major dl-PCB congeners, CB-52, CB-101 were the major indicator PCB congeners, and tetra-CB to hexa-CB were the major homologues for the total input or output materials.

Field study and theoretical evidence for the profiles and underlying mechanisms of PCDD/F formation in cement kilns co-incinerating municipal solid waste and sewage sludge

A field study and theoretical calculations on the profile and formation mechanism of polychlorinated dibenzo-p-dioxins and dibenzofurans (PCDD/Fs) from two cement kilns co-incinerating municipal solid waste and sewage sludge were performed, and the PCDFs were mainly focused. The back-end areas of the cement kilns were identified to be the major sites of PCDD/F formation according to their distributions in particulate samples from different process stages. The proportions of tetra- to hexa-chlorinated dibenzofurans (∑Cl_4-6CDFs) at the kiln back-end areas were in the range of 50-80% of the total PCDD/Fs in mass concentrations and 62-87% in toxic equivalent concentrations. These results indicated that ∑Cl_4-6CDFs are the dominant homologs that should be the focus for reducing PCDD/F emissions in cement kilns that co-incinerate municipal solid waste and sewage sludge. It is speculated that the low contents of oxygen and copper compounds, as well as the alkaline conditions, may contribute to the dominance of ∑Cl_4-6CDFs in the PCDD/Fs formed. Chlorination was assumed to be the mechanism of formation of PCDFs. The results from model predictions and thermodynamic calculations used to test this assumption were consistent with the PCDF profiles observed from the field study.

Concentrations and patterns of polychlorinated biphenyls at different process stages of cement kilns co-processing waste incinerator fly ash

Cement kilns can be used to co-process fly ash from municipal solid waste incinerators. However, this might increase emission of organic pollutants like polychlorinated biphenyls (PCBs). Knowledge of PCB concentrations and homolog and congener patterns at different stages in this process could be used to assess the possibility of simultaneously controlling emissions of polychlorinated dibenzo-p-dioxins and dibenzofurans (PCDD/Fs) and "dioxin-like" compounds. To date, emissions from cement kilns co-processing fly ash from municipal solid waste incinerators have not been analyzed for PCBs. In this study, stack gas and particulate samples from two cement kilns co-processing waste incinerator fly ash were analyzed for PCBs. The average total tri- to deca-chlorinated biphenyl (∑_3-10PCB) concentration in the stack gas samples was 10.15ngm^-3. The ∑_3-10PCB concentration ranges in particulate samples from different stages were 0.83-41.79ngg^-1 for cement kiln 1and0.13-1.69ngg^-1 for cement kiln 2. The ∑_3-10PCB concentrations were much higher in particulate samples from the suspension pre-heater boiler, humidifier tower, and kiln back-end bag filters than in particulate samples from other stages. For these three stages, PCBs contributed to 15-18% of the total PCB, PCDD/F, and polychlorinated naphthalene toxic equivalents in stack gases and particulate matter. The PCB distributions were similar to those found in other studies for PCDD/Fs and polychlorinated naphthalenes, which suggest that it may be possible to simultaneously control emissions of multiple organic pollutants from cement kilns. Homolog patterns in the particulate samples were dominated by the pentachlorobiphenyls. CB-105, CB-118, and CB-123 were the dominant dioxin-like PCB congeners that formed at the back-end of the cement kiln. A mass balance of PCBs in the cement kilns indicated that the total mass of PCBs in the stack gases and clinker was about half the mass of PCBs in the raw materials.

Recycling ash into the first stage of cyclone pre-heater of cement kiln

Fly ash collected from the bag filter could be recycled into the first stage of the cyclone pre-heater of the cement kiln, resulting in the possible enrichment of polychlorinated dibenzo-p-dioxins and dibenzofurans (PCDD/Fs). In this study, soxhlet fly ash (SFA) and raw meal (RM) were selected as the basis for the PCDD/F formation experiments. The levels of 2,3,7,8-PCDD/Fs formed on the SFA and RM were observed to be 2550pg/g (157pg I-TEQ/g) and 1142pg/g (55pg I-TEQ/g), respectively. While less 2,3,7,8-PCDD/Fs was detected when SFA was mixed with RM, suggesting that recycling cement kiln ash would not largely increase the concentration of PCDD/Fs in flue gas. Furthermore, the possible influencing factors on the PCDD/F formation were also investigated. The formation of 2,3,7,8-PCDD/Fs was up to 10,871pg/g (380pg I-TEQ/g) with the adding of CuCl2, which was much higher than the results of CuO and activated carbon. Most importantly, the homologue, congener and gas/particle distribution of PCDD/Fs indicated that de novo synthesis was the dominant PCDD/F formation pathway for SFA. Lastly, principal component analysis (PCA) was also conducted to identify the relationship between the compositions of reactant and the properties of PCDD/Fs produced.

Effects of bypass system on PCDD/F emission and chlorine circulation in cement kilns

A bypass at the kiln inlet allows the effective reduction of alkali chloride cycles and thus perhaps affects the emission of PCDD/Fs. Effects of bypass system on PCDD/F emission and chlorine circulation were studied in two typical dry cement kilns with 5000 ton/day clinker capacity in China and named CK1 and CK2, respectively. Firstly, the emission level of PCDD/Fs with the operation of bypass system was estimated in CK1, to certify that bypass system has a perfect adaption to the cement kiln regarding the PCDD/F emission even with the refuse derived fuel (RDF) as the replacement of fuel. On the other hand, the operating conditions in the CK2 were scrutinised by monitoring the concentrations of SO2, NH3 and HCl. In addition, the characteristics of raw meal, clinker, bag filter ash and bypass ash were also investigated by Energy Dispersive Spectrometer (EDS), metal and chlorine analysis. The balance of chlorine showed that 18 % of the possible accumulated chlorine could be ejected from the cement kiln system when 2 % of kiln exhaust gas was extracted. Furthermore, the emission level of PCDD/Fs in the main flue gas also decreased from 0.037 ± 0.035 ng I-TEQ/Nm(3) to 0.019 ± 0.007 ng I-TEQ/Nm(3) with a reduction efficiency of 48.2 %. Most importantly, PCDD/F emission from the bypass system was proven to have rather minor effect on the total emission factor. The congener distributions of PCDD/Fs were also analysed in the flue gas and fly ash, before and after application of bypass system, to find cues to the formation mechanism.

Variations and factors that influence the formation of polychlorinated naphthalenes in cement kilns co-processing solid waste

Pilot studies of unintentionally produced pollutants should be performed before waste being co-processed in cement kilns. Polychlorinated naphthalene (PCN) formation and emission from cement kilns co-processing sorted municipal solid waste, sewage sludge, and waste acid, however, have not previously been studied. Here, PCNs were analyzed in stack gas samples and solid samples from different stages of three cement production runs. PCN destruction efficiencies were higher when waste was co-processed (93.1% and 88.7% in two tests) than when waste was not co-processed (39.1%), so co-processing waste would not increase PCN outputs. The PCN concentrations were higher in particle samples from the C1 preheater and stages at back end of kiln than in particle samples from other stages, suggesting that cyclone preheater and back end of kiln should be focused for controlling PCN emissions. Besides that, based on the variation of PCN concentrations and corresponding operating conditions in different stages, the temperature, feeding materials, and chlorine content were suggested as the main factors influencing PCN formation. The PCN homologue and congener profiles suggested chlorination and dechlorination were the main PCN formation and decomposition pathways, and congeners CN-23, CN-46, and CN-59 appear to be appropriate indicators of PCNs emitted from coal-burning sources.

Effects of co-processing sewage sludge in cement kiln on NOx, NH3 and PAHs emissions

The effects of co-processing sewage sludge in cement kiln on NOx, NH3 and PAHs emissions were systematically investigated in a cement production line in Beijing. The results show that co-processing the sewage sludge was helpful to reduce NOx emission, which primarily depends on the NH3 amount released from the sewage sludge. Meanwhile, NOx and NH3 concentrations in the flue gas have a negative correlation, and the contribution of feeding the sewage sludge to NOx removal decreased with the increase of injection amount of ammonia water in the SNCR system. Therefore, it is suggested that the injection amount of ammonia water in SNCR system may reduce to cut down the operating costs during co-processing the sewage sludge in cement kiln. In addition, the emission of total PAHs seems to increase with the increased amount of the sewage sludge feeding to the cement kiln. However, the distributions of PAHs were barely changed, and lower molecular weight PAHs were mainly distributed in gaseous phase, accounted for the major portion of PAHs when co-processing sewage sludge in cement kiln.

Distributions, profiles and formation mechanisms of polychlorinated naphthalenes in cement kilns co-processing municipal waste incinerator fly ash

Co-processing municipal solid waste incinerator (MSWI) fly ash in cement kilns is challenging because the unintentional production of persistent organic pollutants (POPs) during the process is not well understood. The distributions, profiles and formation mechanisms of polychlorinated naphthalenes (PCNs) as new POPs covered under Stockholm Convention in two cement kilns co-processing MSWI fly ash were studied. The average concentrations of PCNs in stack gas samples were 710 ng m(-3). The PCN concentration in particle samples collected from different process stages in the cement kilns ranged from 1.1 to 84.7 ng g(-1). Three process sites including suspension pre-heater boiler, humidifier tower, and the kiln back-end bag filter were identified to be the major formation sites of PCNs in cement kilns co-processing MSWI fly ash. The PCN distribution patterns were similar to that of polychlorinated dibenzo-p-dioxin and dibenzofuran (PCDD/Fs), which indicates the possibility for simultaneous control of PCNs and PCDD/Fs in cement kilns co-processing fly ash. Chlorination was suggested to be an important formation mechanism of PCNs, and chlorination pathways of PCN congeners are proposed based on the congener profiles. Thermodynamic calculations, including relative thermal energies (ΔE) and standard free energy of formation (ΔG), and the charge densities of the carbon atoms in PCN supported the proposed chlorination mechanisms for PCN formation. The results presented in this study might provide helpful information for developing techniques and strategies to control PCN emissions during cement kilns co-processing MSWI fly ash.

Emission and distribution of PCDD/Fs and CBzs from two co-processing RDF cement plants in China

An analysis of the emission and distribution characteristics of polychlorinated dibenzo-p-dioxins and dibenzofurans (PCDD/Fs) and chlorobenzenes (CBzs) from two cement kilns (CK1 and CK2) is done. Six measurements in CK1 showed an increase of PCDD/F emission from 76 to 97 pg I-TEQ/Nm(3) after feeding 10 ton/h RDF (refuse derived fuel). For CK2, the effect of increasing the RDF substitution rates from 0 to 21 t/h on the emission of PCDD/Fs was investigated. The correlation analysis indicated that replacing parts of the conventional fuel with RDF could not increase the emission of PCDD/Fs. Furthermore, the gas/particle partitions of PCDD/Fs and CBzs in stack gas were investigated, indicating that PCDD/Fs and CBzs were more associated in gas phase, especially for the lower chlorinated ones. Moreover, the bag filter fly ash was characterized by its particle distribution, XRD- and EDS-analysis. Additionally, the level of PCDD/Fs in outflowing fly ash escalates for smaller particle size. In order to evaluate the environmental effect on inhabitants, the levels of PCDD/Fs were also determined in samples of ambient air collected in the vicinity of CK2 (~200 m).

A review on paint sludge from automotive industries: Generation, characteristics and management

The automotive manufacturing process results in the consumption of several natural sources and the generation of various types of wastes. The primary source of hazardous wastes at an automotive manufacturing plant is the painting process, and the major waste fraction is paint sludge, which is classified with EU waste code of 080113* implying hazardous characteristics. The amount of the paint sludge generated increases every year with the worldwide increase in the car production. The characteristics of the paint sludge, which mainly designate the management route, are mainly determined by the type of the paint used, application technique employed, and the chemicals applied such as flocculants, detackifiers, pH boosters, antifoam agents, and biocides as well as the dewatering techniques preferred. Major routes for the disposal of the paint sludges are incineration as hazardous waste or combustion at cement kilns. Because of high dissolved organic carbon content of the paint, the paint sludge cannot be accepted by landfills according to European Union Legislations. More investigations are needed in the field of paint sludge recycling such as recycling it as a new paint or as other formulations, or making use of the sludge for the production of construction materials. Research on the applicability of the paint sludge in composting and biogasification can also be useful. Ongoing research is currently being conducted on new application techniques to increase the effectiveness of paint transfer, which helps to prevent the generation of paint sludge. Advancements in paint and coating chemistry such as the reduction in the coating layers with its thickness also help to decrease the level of paint sludge generation. Investigations on the effects of the chemicals on the recycling potential of paint sludges and consideration of these effects by the chemical manufacturer companies would be extremely important. This review presents the formation of paint sludge, the factors affecting its characteristics, common disposal routes, the findings of the field trips to automotive manufacturing plants in Turkey, and a summary of the characterization findings of the paint sludge samples from a plant in Turkey.

Case study of an MBT plant producing SRF for cement kiln co-combustion, coupled with a bioreactor landfill for process residues

The paper describes the performances of the energy recovery pathway from the residual waste based on the production of a Solid Recovered Fuel (SRF) to be exploited via co-combustion in a cement kiln. The SRF is produced in a single stream Mechanical-Biological Treatment plant, where bio-drying of the waste is followed by mechanical refining in order to fulfil the quality requirements by the cement kilns. Peculiar of this MBT is the fact that sorting residues are disposed in a nearby landfill, managed according to a bioreactor approach, where landfill gas is collected for electric energy recovery. A detailed mass and energy balance of the system is presented based on one year operational data, followed by its Life Cycle Assessment. Results show that the system is energetically and environmentally effective, with most of the impacts being more than compensated by the savings of materials and energy. Major role in determining such outcome is the displacement of petcoke in the cement kiln, both in terms of its fossil CO2 emissions and of its life cycle impacts, including the trans-oceanic transport. To check the robustness of the results, two sensitivity analyses are performed on the landfill gas collection efficiency and on the avoided electric energy mix.

Field pilot study on emissions, formations and distributions of PCDD/Fs from cement kiln co-processing fly ash from municipal solid waste incinerations

A pilot study was performed to evaluate formation, distribution and emission of polychlorinated dibenzo-p-dioxins and dibenzofurans (PCDD/Fs) from cement kilns that co-process fly ash from municipal solid waste incineration (MSWI). Stack gas and particulate samples from multiple stages in the process were collected and analyzed for PCDD/Fs. Stack emissions of PCDD/Fs were below the European Union limit for cement kilns (0.1 ng TEQ m(-3)). PCDD/F concentrations in particulates from the cyclone preheater outlet, suspension preheater boiler, humidifier tower, and back-end bag filter were much higher than in other samples, which suggests that these areas are the major sites of PCDD/F formation. Comparison of PCDD/F homolog and congener profiles from different stages suggested that tetra- and penta-chlorinated furans were mainly formed during cement kiln co-processing of MSWI fly ash. Three lower chlorinated furan congeners, including 2,3,7,8-tetrachlorodibenzofuran, 1,2,3,7,8-pentachlorodibenzo-p-dioxin and 2,3,4,7,8-pentachlorodibenzofuran, were identified as dominant contributors to the toxic equivalents (TEQ) of the PCDD/Fs. The concentration of PCDD/Fs in particulates was correlated with chloride content, which is consistent with its positive effect on PCDD/F formation. This could be mitigated by pretreating the feedstock to remove chloride and metals. Mass balance indicated that cement kilns eliminated about 94% of the PCDD/F TEQ input from the feedstock.

Disposal of historically contaminated soil in the cement industry and the evaluation of environmental performance

Approximately 400000t of DDTs/HCHs-contaminated soil (CS) needed to be co-processed in a cement kiln with a time limitation of 2y. A new pre-processing facility with a "drying, grinding and DDTs/HCHs vaporizing" ability was equipped to meet the technical requirements for processing cement raw meal and the environmental standards for stack emissions. And the bottom of the precalciner with high temperatures >1000°C was chosen as the CS feeding point for co-processing, which has rarely been reported. To assess the environmental performance of CS pre- and co-processing technologies, according to the local regulation, a test burn was performed by independent and accredited institutes systematically for determination of the clinker quality, kiln stack gas emissions and destruction efficiency of the pollutant. The results demonstrated that the clinker was of high quality and not adversely affected by CS co-processing. Stack emissions were all below the limits set by Chinese standards. Particularly, PCDD/PCDF emissions ranged from 0.0023 to 0.0085ngI-TEQNm(-3). The less toxic OCDD was the peak congener for CS co-processing procedure, while the most toxic congeners (i.e. 2,3,7,8-TeCDD, 1,2,3,7,8-PeCDD and 2,3,4,7,8-PeCDD) remained in a minor proportion. Destruction and removal efficiency (DRE) and destruction efficiency (DE) of the kiln system were better than 99.9999% and 99.99%, respectively, at the highest CS feeding rate during normal production. To guarantee the environmental performance of the system the quarterly stack gas emission was also monitored during the whole period. And all of the results can meet the national standards requirements.

Mass balance of dioxins over a cement kiln in China

The cement production process may be a potential source of polychlorinated dibenzo-p-dioxins and dibenzofurans (PCDD/Fs, "dioxins"), due to the widespread distribution of dioxins and potential precursors in raw materials and to conditions favorable to de novo formation in the heat exchangers. The emission, gas/particle distribution, and mass balance of PCDD/Fs were investigated at a typical state-of-the-art Chinese cement kiln. Input and output inventories were established for three campaigns, including two in normal operation and one while co-processing refuse derived fuel (RDF). Sample analysis from stack gas, cement kiln dust, raw meal, fly dust and clinker for the analysis of PCDD/Fs were reported in this study. Dioxins were also analyzed at various positions in the pre-heater, presenting an adsorption-desorption circulation process of PCDD/Fs. The over-all dioxin mass balance was negative, indicating that this cement kiln is not a source but a sink process of dioxins.

Long-term sampling of dioxin-like substances from a clinker kiln stack using alternative fuels

The aim of this work is to characterize atmospheric emissions of polychlorinated dibenzo-p-dioxins (PCDDs)/polychlorinated dibenzofurans (PCDFs) and dioxin-like polychlorinated biphenyls (dl-PCBs) from a cement production plant where the existing clinker production line was completely replaced by a new state-of-the-art installation. The project started in April 2008 with the installation of a long-term sampling system in the stack of the clinker kiln that used petroleum coke as fuel; PCDD/PCDF and dl-PCB emissions were then evaluated for a two year period. To carry out the second part of the study, in 2010 the sampling system was moved to the new installation in which, apart from conventional fuel, recovered derived fuel (RDF) and WWTP sludge were used as alternative fuels. For both the old and new clinker kilns, PCDD/PCDF emission values were well below the limit established by the European Waste Incineration Directive 2000/76/CE (EWID) of 100 pg I-TEQ/Nm(3); values ranged from 0.43 to 2.02 and from 0.07 to 3.31 pg I-TEQ/Nm(3), respectively. dl-PCBs accounted for approximately 25% of the WHO-TEQ toxicity. These results prove that the installation is capable of reducing PCDD/PCDF and dl-PCB emissions when alternative fuels are integrated into the process. In the case of PCDDs/PCDFs, the major contributions to total TEQ were usually from 2,3,7,8-TCDD (owing to its relative abundance) and 2,3,4,7,8-PeCDF (due to its high I-TEF of 0.5); while for dl-PCBs, the major contribution was from PCB-126. The slight shift in the congener profile between the old and new installations was characterized and a regression model was proposed for dl-PCB emissions depending on the RDF flow rate in the clinker.

Destruction of DDT wastes in two preheater/precalciner cement kilns in China

The destruction of DDT formulations and DDT contaminated soil was conducted by feeding wastes into the flue gas chamber at the kiln inlet of two different preheater/precalciner cement kilns in China. The concentration of DDT, PCDD/PCDFs and HCB were measured in the flue gas of the main stack, in the solid material under baseline conditions and when feeding DDT-wastes. The destruction efficiency and the destruction and removal efficiency for DDT were in the range of 99.9335%-99.9998% and 99.9984%-99.9999%, respectively. The emissions of PCDD/PCDFs and HCB in the flue gas varied in the range of 0.0019-0.0171 ng I-TEQ/Nm(3) and 0.0064-0.0404 μg/Nm(3), respectively. The emission factor for PCDD/PCDF and HCB varied from 0.0137 to 0.0281 μg/ton and from 17.32 to 109.34 μg/ton of clinker, respectively. The concentration of PCDD/PCDFs and HCB in solid samples decreased as follows: cement kiln dust, 4.1-5 ng I-TEQ/kg and 0.70-0.71 μg/kg, respectively; >raw meal, 0.82-0.97 ng I-TEQ/kg and 0.18 μg/kg, respectively; >cement clinker, 0.09-0.22 ng I-TEQ/kg and 0.14-0.18 μg/kg, respectively. This study indicates that the feeding of DDT and POPs-wastes to the lower temperature part of a cement kiln system possibly to create a buildup of trace not-destroyed compounds in the system and might cause emissions; the technical feasibility and the environmental acceptability of this practice need to be investigated thoroughly.